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Lincoln Electric V250-S manual

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Table of contents for the manual

  • Page 1

    INVER TEC V250-S SER VICE MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors SVM124-A July, 1996 Safety Depends on You Lincoln arc welding and cutting equipmen[...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. U[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommen[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour [...]

  • Page 6

    INVERTEC V250-S vi MASTER T ABLE OF CONTENTS FOR ALL SECTIONS PAGE INSTALLATION .......................................................................................................................SECTION A TECHNICAL SPECIFICATIONS ..................................................................................................A-2 SAFETY PRECAUT[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION-A-1 INST ALLA TION INVERTEC V250-S SECTION-A-1 T ABLE OF CONTENTS -INST ALLA TION SECTION- TECHNICAL SPECIFICATIONS ..................................................................................................A-2 SAFETY PRECAUTIONS .....................[...]

  • Page 8

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 INST ALLA TION INVERTEC V250-S A-2 Height Width Depth Weight 15.0 in. 9.1 in. 19.7 in. 36 lbs. 381 mm 231 mm 500 mm 17 Kg PHYSICAL DIMENSIONS THREE PHASE SINGLE PHASE Standar[...]

  • Page 9

    A-3 INST ALLA TION INVERTEC V250-S A-3 Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and ser- vice this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • Be sure to discha[...]

  • Page 10

    A-4 INST ALLA TION INVERTEC V250-S A-4 POWER INPUT CONNECTION FOR 50/60 HZ MACHINES 1. Connect terminal marked to earth ground per National Electric Code. 2. Connect the supply lines to the line switch. Torque to 3.0 Nm. 3 . Install in accordance with all local and national electric codes. The Invertec V250-S 50/60 Hz machine is supplied with one c[...]

  • Page 11

    A-5 INST ALLA TION INVERTEC V250-S A-5 OUTPUT CONNECTIONS Refer to figure A.2 for the location of the 6 Pin Remote Receptacle and the Output Terminals. FIGURE A.2 OUTPUT CONNECTIONS REMOTE CONTROL RECEPT ACLE Remote control (K857), Arc start switch (K814), Hand amptrol (K963) and Foot amptrol (K870) connect directly to 6 pin amphenol on the front o[...]

  • Page 12

    A-6 NOTES INVERTEC V250-S A-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 13

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION INVERTEC V250-S SECTION-B-1 SECTION-B-1 T ABLE OF CONTENTS -OPERA TION SECTION- SAFETY INSTRUCTIONS ...........................................................................................................B-2 GENERAL DESCRIPTION ........................[...]

  • Page 14

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 OPERA TION B-2 GENERAL DESCRIPTION The Invertec V250-S is a 250 amp arc welding power source that utilizes single or three phase input power, to produce constant current outp[...]

  • Page 15

    B-3 OPERA TION B-3 1. Power Switch - Place the lever in the “ON” position to energize the machine. When the power is on, the fan will operate and the output will be energized in SMAW modes. GTAW mode requires remote trig- ger to energize the output. 2. Output Control - This controls the output current. Control is provided over the entire output[...]

  • Page 16

    B-4 OPERA TION B-4 6. Arc Force - This control functions in SMAW modes to adjust the Arc Force. The arc is soft at the mini- mum settings and more forceful or driving at the maximum settings. Higher spatter levels may be present at the maximum settings. 7. Output Terminals - These quick disconnect termi- nals provide connection points for the elect[...]

  • Page 17

    B-5 OPERA TION B-5 P ARALLEL OPERA TION The Invertec’s are operable in parallel. For best results, the currents of each machine should be rea- sonably well shared. As an example, with two machines set up in parallel for a 300 amp procedure, each machine should be set to deliver approximately 150 amps, not 200 amps from one and 100 amps from the o[...]

  • Page 18

    B-6 NOTES INVERTEC V250-S B-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 19

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION C-1 ACCESSORIES SECTION C-1 INVERTEC V250-S T ABLE OF CONTENTS -ACCESSORIES SECTION- OPTIONS / ACCESSORIES ........................................................................................................C-2 CABLE PLUGS ...............................[...]

  • Page 20

    C-2 ACCESSORIES C-2 OPTIONS / ACCESSORIES CABLE PLUGS K852-70 - Cable Plug Kit for 1/0-2/0 cable. Attaches to welding cable to provide quick disconnect from machine. K852-95 - Cable Plug Kit for 2.0-3/0 cable. NOTE: Two K852-70 plugs are included with the V250-S. REMOTE CONTROLS K857 - Remote Output Control for stick welding. K963 - Hand Amptrol tm[...]

  • Page 21

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION D-1 MAINTENANCE SECTION D-1 INVERTEC V250-S T ABLE OF CONTENTS -MAINTENANCE SECTION- INPUT FILTER CAPACITOR DISCHARGE PROCEDURE .........................................................D-2 ROUTINE MAINTENANCE .................................................[...]

  • Page 22

    D-2 MAINTENANCE D-2 INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE 1 . Turn off input power or disconnect input power lines. 2. Remove the 5/16" hex head screws from the side and top of the machine and remove wrap-around machine cover. 3. Be careful not to make contact with the capacitor terminals that are located in the top and bottom of the Po[...]

  • Page 23

    D-3 MAINTENANCE D-3 ROUTINE MAINTENANCE 1 . Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best. 2. Remove the machine wrap-around cover and per- form the input filter capacitor discharge procedure (detail[...]

  • Page 24

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-4 MAINTENANCE D-4 INVERTEC V250-S FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. POWER PC BOARD CONTROL PC BOARD INPUT RECTIFIER OUTPUT RECTIFIER HEA TSINK FINS MAIN TRA[...]

  • Page 25

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-1 THEOR Y OF OPERA TION E-1 INVERTEC V250-S T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- GENERAL DESCRIPTION ...........................................................................................................E-2 INPUT LINE VOLTAGE ...................[...]

  • Page 26

    E-2 THEOR Y OF OPERA TION E-2 INPUT LINE VOL T AGE The single-phase or three-phase input power of 208, 230 or 460 volts AC is connected to the machine, through a line switch located on the front panel. A reconnect panel and switch allows the user to con- figure the machine for either a low or high input volt- age and also connect the auxiliary tran[...]

  • Page 27

    E-3 THEOR Y OF OPERA TION E-3 PRECHARGE AND PROTECTION The input voltage is rectified and the DC voltage is applied, through the reconnect switch, to the power board. The power board contains precharging circuit- ry for the safe charging of the input filter capacitors. Once the capacitors are precharged and balanced the control board activates the [...]

  • Page 28

    E-4 THEOR Y OF OPERA TION E-4 MAIN TRANSFORMER Each IGBT pair acts as a switch assembly. Each assembly feeds a separate, oppositely wound primary winding of the main transformer. The reverse direc- tions of current flow through the main transformer pri- maries and the offset timing of the IGBT pairs induce an AC square wave output signal at the sec[...]

  • Page 29

    E-5 THEOR Y OF OPERA TION E-5 OUTPUT RECTIFICA TION AND CONTROL The AC output from the main transformer secondary is rectified to a DC output and applied to the output terminals. Output voltage and current feedback infor- mation, which is fed to the control board, is sensed at the output terminals and shunt. The control board monitors the panel con[...]

  • Page 30

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-6 THEOR Y OF OPERA TION E-6 PROTECTION CIRCUITS Protective circuits are designed into the V250-S machine to sense trouble and shut down the machine before the trouble damages t[...]

  • Page 31

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-7 THEOR Y OF OPERA TION E-7 INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor. IGBTs are semicon- ductors well suited for high frequency sw[...]

  • Page 32

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-8 THEOR Y OF OPERA TION E-8 PULSE WIDTH MODULA TION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative port[...]

  • Page 33

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V250-S SECTION F-1 TROUBLESHOOTING & REP AIR SECTION F-1 T ABLE OF CONTENTS -TROUBLESHOOTING & REP AIR SECTION- TROUBLESHOOTING AND REPAIR SECTION.........................................................................SECTION F HOW TO USE TROUBLESH[...]

  • Page 34

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V250-S F-2 TROUBLESHOOTING & REP AIR F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-[...]

  • Page 35

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V250-S F-3 TROUBLESHOOTING & REP AIR F-3 _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems ca[...]

  • Page 36

    F-4 TROUBLESHOOTING & REP AIR F-4 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2[...]

  • Page 37

    F-5 TROUBLESHOOTING & REP AIR F-5 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2[...]

  • Page 38

    F-6 TROUBLESHOOTING & REP AIR F-6 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2[...]

  • Page 39

    F-7 TROUBLESHOOTING & REP AIR F-7 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2[...]

  • Page 40

    F-8 TROUBLESHOOTING & REP AIR F-8 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2[...]

  • Page 41

    F-9 TROUBLESHOOTING & REP AIR F-9 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2[...]

  • Page 42

    F-10 NOTES INVERTEC V250-S F-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V250-S F-11 TROUBLESHOOTING & REP AIR F-11 TEST DESCRIPTION This test will determine if the auxiliary transformer is functional when the correct primary volt- age is[...]

  • Page 44

    F-12 TROUBLESHOOTING & REP AIR F-12 TEST PROCEDURE 1 . Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section 3. Locate the Auxiliary Transformer just behind the input line switch on the lower right side of the machine. 4. Locate and disconnect plug J7 from the wiring harness. 5. C[...]

  • Page 45

    F-13 TROUBLESHOOTING & REP AIR F-13 7. If the correct test voltages are pre- sent the auxiliary transformer is good. 8. If any of the voltages are missing or very low, with the proper primary voltage applied, the auxiliary trans- former may be faulty. Replace. 9. If the auxiliary transformer tests good but does not function when connect- ed to [...]

  • Page 46

    F-14 NOTES INVERTEC V250-S F-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 47

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-15 TROUBLESHOOTING & REP AIR F-15 INVERTEC V250-S TEST DESCRIPTION This test will help determine if the input rectifier has “shorted” or “open” diodes. MA TERIALS N[...]

  • Page 48

    F-16 TROUBLESHOOTING & REP AIR F-16 TEST PROCEDURE 1 . Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Locate Input Rectifier (D9) and lead locations. 4 . With the Phillips head screwdriver remove leads #207, 207A and #209 from the rectifier. See Figure F.2. 5. Use the a[...]

  • Page 49

    F-17 TROUBLESHOOTING & REP AIR F-17 6. If the Input Rectifier does not meet the acceptable readings outlined in Table F.2. the component may be faulty. Replace. Note: Before replacing the Input Rectifier(D9) check the input power switch (S1) and perform the Power Board Resistance Test . Also check for leaky or faulty filter capacitors. 7 . When[...]

  • Page 50

    F-18 NOTES INVERTEC V250-S F-18 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 TROUBLESHOOTING & REP AIR F-19 INVERTEC V250-S TEST DESCRIPTION This test will help determine if the Power Board has any “shorted” or “leaky” power diodes or Ins[...]

  • Page 52

    F-20 TROUBLESHOOTING & REP AIR F-20 TEST DESCRIPTION 1 . Remove main input power to the V250 -S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Locate the Power Board and associ- ated lead locations. See Figure F.3. 4. Carefully remove main transformer primary leads #201, #204, #205 and #208 from the power b[...]

  • Page 53

    F-21 TROUBLESHOOTING & REP AIR F-21 6. If the power board does not meet the acceptable readings outlined in Table F.3. the board may be faulty. Replace. See Power Board Removal and Replacement Procedure . Note: Complete power board and filter capacitor replacement is recommended . 7 . If the power board “passes” the resistance test proceed [...]

  • Page 54

    F-22 NOTES INVERTEC V250-S F-22 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-23 TROUBLESHOOTING & REP AIR F-23 INVERTEC V250-S TEST DESCRIPTION This test will help determine if any of the output diodes are “shorted”. MA TERIALS NEEDED Analog vol[...]

  • Page 56

    F-24 TROUBLESHOOTING & REP AIR F-24 TEST PROCEDURE 1 . Remove main input power to the V250-S. 2. Locate the output terminals on the front panel of the machine. See Figure F.4. 3. Remove any output cables and load from the output terminals. 4. Using the analog ohmmeter test for more than 200 ohms resistance between positive and negative out- put[...]

  • Page 57

    F-25 TROUBLESHOOTING & REP AIR F-25 5. If more than 200 ohms is measured the output diodes are not “shorted”. 6. If less than 200 ohms is measured, one or more output diodes or snub- bers may be shorted or “leaky”. 7. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 8. Locate output diodes and snubbers. See [...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-26 TROUBLESHOOTING & REP AIR F-26 OUTPUT DIODES TEST (continued) INVERTEC V250-S OUTPUT DIODES SNUBBERS Figure F .6 Output Diodes and Snubber Locations (Codes 10102 and 101[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-27 TROUBLESHOOTING & REP AIR F-27 INVERTEC V250-S TEST DESCRIPTION This test will aid the technician in determining if the voltage board or some other machine component may[...]

  • Page 60

    F-28 TROUBLESHOOTING & REP AIR F-28 TEST PROCEDURE 1 . Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Locate and familiarize yourself with the leads and pin locations in plug J6 on the power board. See Figure F.8. 4. The following tests will be performed with the input [...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-29 TROUBLESHOOTING & REP AIR F-29 POWER BOARD VOL T AGE TEST (continued) INVERTEC V250-S T ABLE F .4. Power Board V oltage T est Points. TEST DESCRIPTION The PWM pulse driv[...]

  • Page 62

    F-30 NOTES INVERTEC V250-S F-30 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-31 TROUBLESHOOTING & REP AIR F-31 INVERTEC V250-S TEST DESCRIPTION This test will aid the technician in determining if the control board or some other machine component may[...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-32 TROUBLESHOOTING & REP AIR F-32 INVERTEC V250-S TEST PROCEDURE 1 . Remove main input power to the V250-S. 2 . Perform Filter Capacitor Discharge Procedure detailed in Mai[...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-33 TROUBLESHOOTING & REP AIR F-33 CONTROL BOARD VOL T AGE TEST (continued) INVERTEC V250-S T ABLE F .5. Control Board V oltage T est Points. TEST DESCRIPTION The 18VAC from[...]

  • Page 66

    F-34 NOTES INVERTEC V250-S F-34 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-35 TROUBLESHOOTING & REP AIR F-35 INVERTEC V250-S TEST DESCRIPTION This check will aid the technician in the understanding and evaluation of the V250-S protec- tion circuit[...]

  • Page 68

    F-36 TROUBLESHOOTING & REP AIR F-36 TEST PROCEDURE 1 . Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Locate and familiarize yourself with the leads and pin locations in plug J2 on the control board and also plug J6 on the power board. See Figures F.10. and F.11. PROTEC[...]

  • Page 69

    F-37 TROUBLESHOOTING & REP AIR F-37 4. The following tests will be performed with the input power applied to the V250-S. BE CAREFUL. ALWAYS REMOVE INPUT POWER AND PERFORM FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY MACHINE COMPONENT. 5. Apply input power and turn ON the V250-S. 6 . Check for 0 to 1 VDC at leads #311(4J6)+ to #313(5[...]

  • Page 70

    F-38 NOTES INVERTEC V250-S F-38 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 71

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-39 TROUBLESHOOTING & REP AIR F-39 INVERTEC V250-S TEST DESCRIPTION This test will help the technician to determine if the input filter capacitors are being charged equally [...]

  • Page 72

    F-40 TROUBLESHOOTING & REP AIR F-40 TEST PROCEDURE 1 . Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3 . Put the mode switch S2 in the SMAW (soft) position and put the Local/Remote switch S3 in the LOCAL position. 4 . Put the Output Control R3 at the minimum position. 5. [...]

  • Page 73

    F-41 TROUBLESHOOTING & REP AIR F-41 8. Check for the appropriate voltages outlined in Table F.6. Note: Voltages may vary with the input line voltage. In the event the capacitor voltage is too high or not balanced (within 20VDC) the protection circuit will pre- vent output. The overvoltage trip set- ting is nominal line voltage (230/460) +15%. R[...]

  • Page 74

    F-42 NOTES INVERTEC V250-S F-42 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 75

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-43 TROUBLESHOOTING & REP AIR F-43 INVERTEC V250-S MA TERIALS NEEDED Small needle-nose pliers Small screwdriver 5/16” nut-driver CONTROL BOARD REMOV AL AND REPLACEMENT Ser[...]

  • Page 76

    F-44 TROUBLESHOOTING & REP AIR F-44 PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Locate the control board and the five molex type plugs that are connected to it. See Figure F.13. 4. Carefully remove the five molex type plugs by depressing the locking tabs and [...]

  • Page 77

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-45 TROUBLESHOOTING & REP AIR F-45 INVERTEC V250-S MA TERIALS NEEDED 5/16” nut-driver 1/4” nut-driver 7/16” wrench 3/16” Allen type wrench POWER BOARD REMOV AL AND R[...]

  • Page 78

    F-46 TROUBLESHOOTING & REP AIR F-46 PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Locate the power board, the molex type plug J6, the five leads with push-on connectors and the four capacitor leads that are connected to the power board. 4. Carefully remove lead[...]

  • Page 79

    F-47 TROUBLESHOOTING & REP AIR F-47 7. Using the 1/4” nut-driver remove the two screws holding the P.C. board to the heat sink mounting bracket. 8. With the 3/16” Allen wrench remove the four socket head cap screws and washers holding the power board to the large aluminum heat sink. 9 . Carefully remove the power board taking note as to the[...]

  • Page 80

    F-48 NOTES INVERTEC V250-S F-48 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 81

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-49 TROUBLESHOOTING & REP AIR F-49 INVERTEC V250-S MA TERIALS NEEDED 5/16” nut-driver Slot head screwdriver FIL TER CAP ACITOR REMOV AL AND REPLACEMENT Service and repair [...]

  • Page 82

    F-50 TROUBLESHOOTING & REP AIR F-50 PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3 . Perform Power Board Removal Procedure in this section. 4 . Using the 5/16’ nut-driver remove the two screws from the top rear of the case back. See Figure F.15. 5 . Using the 5[...]

  • Page 83

    F-51 TROUBLESHOOTING & REP AIR F-51 7. Once the top of the bracket assem- bly is disengaged from the top center panel the bracket assembly can be removed from the bottom of the case by sliding the bracket assembly towards the front of the machine. The locking tab on the bottom of the bracket will have to be lifted slightly to enable the assembl[...]

  • Page 84

    F-52 NOTES INVERTEC V250-S F-52 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-53 TROUBLESHOOTING & REP AIR F-53 INVERTEC V250-S MA TERIALS NEEDED 3/16” Allen type wrench Phillips head screwdriver 7/16” Box wrench Torque wrench INPUT RECTIFIER BRI[...]

  • Page 86

    F-54 TROUBLESHOOTING & REP AIR F-54 PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3 . Locate the input rectifier and the leads connected to it. See Figure F.16. 4. Identify and mark the leads connect- ed to the rectifier terminals. 5 . With the Phillips head screw[...]

  • Page 87

    F-55 TROUBLESHOOTING & REP AIR F-55 7. Carefully remove the input rectifier bridge. 8. When installing a new input rectifier apply a thin coating of Dow Corning 340 Heat Sink Compound (Lincoln E1868) to the mating surfaces. Torque the mounting cap screws and nuts to 44 IN-LBS. 9. Reconnect the eight leads to the cor- rect terminals and torque t[...]

  • Page 88

    F-56 NOTES INVERTEC V250-S F-56 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-57 TROUBLESHOOTING & REP AIR F-57 INVERTEC V250-S MA TERIALS NEEDED Slot head screwdriver 5/16” nut-driver 7/16” wrench Wire cutters 3/8” wrench OUTPUT DIODE ASSEMBL [...]

  • Page 90

    F-58 TROUBLESHOOTING & REP AIR F-58 PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Locate output diode assembly and associated leads. See Figure F.17. 4. Cut the necessary wire ties and slide the sleeving from the four wire con- nections to be disassembled. See [...]

  • Page 91

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-59 TROUBLESHOOTING & REP AIR F-59 INVERTEC V250-S 10. Using the slot head screwdriver carefully disengage the output diode heat sink mounting bracket from the top center pa[...]

  • Page 92

    F-60 NOTES INVERTEC V250-S F-60 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 93

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-61 TROUBLESHOOTING & REP AIR F-61 INVERTEC V250-S MA TERIALS NEEDED 7/16” wrench 1/8” Allen type wrench Torque wrench OUTPUT DIODE ASSEMBL Y REMOV AL AND REPLACEMENT (M[...]

  • Page 94

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-62 TROUBLESHOOTING & REP AIR F-62 INVERTEC V250-S PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Sec[...]

  • Page 95

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-63 TROUBLESHOOTING & REP AIR F-63 INVERTEC V250-S 6. Using 7/16” wrench remove the top and bottom mounting bolts and associated washers from the diode module to be replac[...]

  • Page 96

    F-64 NOTES INVERTEC V250-S F-64 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 97

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-65 TROUBLESHOOTING & REP AIR F-65 INVERTEC V250-S MA TERIALS NEEDED 7/16” Wrench 3/8” Wrench Wire cutters 3/4” Wrench Slot head screwdriver MAIN TRANSFORMER REMOV AL [...]

  • Page 98

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-66 TROUBLESHOOTING & REP AIR F-66 INVERTEC V250-S PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Sec[...]

  • Page 99

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-67 TROUBLESHOOTING & REP AIR F-67 INVERTEC V250-S 6 . Disconnect and clear the shunt sensing leads from the control board (plug J4). 7 . Disconnect the thermostat leads fro[...]

  • Page 100

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-68 TROUBLESHOOTING & REP AIR F-68 INVERTEC V250-S MAIN TRANSFORMER REMOV AL AND REPLACEMENT (MACHINE CODES BELOW 10150) (continued) MAIN TRANSFORMER  MOUNTING SCREWS MAI[...]

  • Page 101

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-69 TROUBLESHOOTING & REP AIR F-69 22. Reassemble the shunt assembly to the negative output terminal. Take note of the by-pass connection on the negative terminal. Clear lea[...]

  • Page 102

    F-70 NOTES INVERTEC V250-S F-70 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 103

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-71 TROUBLESHOOTING & REP AIR F-71 INVERTEC V250-S MA TERIALS NEEDED 7/16” Wrench 3/8” Wrench Wire cutters 3/4” Wrench Slot head screwdriver MAIN TRANSFORMER REMOV AL [...]

  • Page 104

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-72 TROUBLESHOOTING & REP AIR F-72 INVERTEC V250-S PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Sec[...]

  • Page 105

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-73 TROUBLESHOOTING & REP AIR F-73 INVERTEC V250-S 7 . Disconnect the thermostat leads from the thermostat mounted on the shunt assembly. 8 . With the 3/4” wrench remove t[...]

  • Page 106

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-74 TROUBLESHOOTING & REP AIR F-74 INVERTEC V250-S MAIN TRANSFORMER REMOV AL AND REPLACEMENT (MACHINE CODES ABOVE 10150) (continued) MAIN TRANSFORMER  MOUNTING SCREWS MAI[...]

  • Page 107

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-75 TROUBLESHOOTING & REP AIR F-75 INVERTEC V250-S 21. With the 3/4” wrench assemble the positive output lead to the positive output terminal. Take note of the by-pass con[...]

  • Page 108

    F-76 NOTES INVERTEC V250-S F-76 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 109

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-77 TROUBLESHOOTING & REP AIR F-77 RETEST AFTER REP AIR INVERTEC V250-S Should a machine under test be rejected for any reason requiring the removal of any mechanical part t[...]

  • Page 110

    F-78 NOTES INVERTEC V250-S F-78 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 111

    G-1 ELECTRICAL DIAGRAMS G-1 INVERTEC V250-S Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram (Codes 10102, 10103) . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Wiring Diagram (Codes[...]

  • Page 112

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES INVERTEC V250-S[...]

  • Page 113

    G-2 ELECTRICAL DIAGRAMS INVERTEC V250S Wiring Diagram (Codes 10102, 10103) ELECTRICAL SYMBOLS PER E1537 H1 18V 76 C B A F 75 76 77 GND REMOTE CONTROL RECEPTACLE MIN T3 T2 OFF ON H1 I I TP5 B W TP4 C6 C5 311 313 W B 376 330 303 327 304 303 303A 305 1 2 3 377 376 330 303A LOCAL REMOTE 327 328 J4 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPON[...]

  • Page 114

    G-3 ELECTRICAL DIAGRAMS INVERTEC V250S Wiring Diagram (Codes 10187, 10188) ELECTRICAL SYMBOLS PER E1537 H1 18V 76 C B A F 75 76 77 GND REMOTE CONTROL RECEPTACLE MIN T3 T2 OFF ON H1 I I TP5 B W TP4 C6 C5 311 313 W B 376 330 303 327 304 303 303A 305 1 2 3 377 376 330 303A LOCAL REMOTE 327 328 J4 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPON[...]

  • Page 115

    G-4 ELECTRICAL DIAGRAMS INVERTEC V250S Control PC Board (G2666) Layout ITEM REQ'D PART NO. IDENTIFICATION CAPACITORS = MFD/VOLTS RESISTORS = OHMS J2 J3 J4 X1 TP1 D3 D2 D4 D1 D6 C2 C3 R11 R12 C4 R10 X2 X4 R16 R15 R7 R8 DZ4 DZ2 C5 C10 C20 C6 C7 R4 Q1 X3 C18 R20 R19 C17 R26 R27 R25 R24 C24 D16 D18 D17 D15 R40 C22 R28 R29 C9 C8 R13 R14 R18 R17 R49[...]

  • Page 116

    G-5 ELECTRICAL DIAGRAMS INVERTEC V250S Power PC Board (G2684) Layout CAPACITORS = MFD/VOLTS RESISTORS = OHMS ITEM REQ'D PART NO IDENTIFICATION T1 B206 B203A B202A B207A C1 DZ1 DZ2 DZ3 R1 R2 R3 R4 R5 R6 R12 R13 R14 R15 R16 R17 R19 DZ4 C4 Q1 OCI1 R20 DZ5 DZ6 DZ7 R21 R22 R23 R24 C5 R25 R34 R35 R37 C7 X2 R41 DZ9 DZ10 DZ11 R42 R43 R44 R45 R46 C8 C3[...]

  • Page 117

    G-6 ELECTRICAL DIAGRAMS INVERTEC V250S Control PC Board (G2666) Schematic 50V 0.1 C6 50V 0.1 C10 1.50K R34 NC GND S V OUT IN OUT GND V S X4 3 4 7 5 1 6 8 2 NC GND S V OUT IN OUT GND V S X2 3 4 7 5 1 6 8 2 267 R7 1W 12V DZ4 1.0A 30V D35 4.7 35V C7 50V 0.1 C5 1W 12V DZ2 1.0A 30V D7 50V 0.1 C20 1.0A 30V D8 267 R15 3300 50V C2 THERMAL 332K R67 1W 20V D[...]

  • Page 118

    G-7 ELECTRICAL DIAGRAMS INVERTEC V250S Power PC Board (G2684) Schematic 325VDC E (NOMINAL) FILTER 207A RECONNECT G2 S2 G1 S1 G3 S4 S3 G4 A B J6 1 DRIVE GATE GATE GATE GATE T1 6 5 7 8 3 10 9 4 1 12 J6 2 325VDC TRANSFORMER PRIMARY L TRANSFORMER D PRIMARY FROM BOARD CONTROL (NOMINAL) 208 9304 RECONNECT 1W 15V DZ2 1.00K R3 1.00K R4 FILTER 205 C (PWM DR[...]